Method of securing a tire-based unit of a tire condition sensing system to a rim and an associated apparatus

ABSTRACT

A method of securing a tire-based unit ( 24 ) of a tire condition sensing system ( 12 ) to a rim ( 60 ) and an associated apparatus ( 62 ) are provided. The method comprising the steps of: position a mounting bracket ( 124 ) on the rim ( 60 ); positioning a punch ( 140 ) against the mounting bracket ( 124 ) so that a portion of the mounting bracket ( 124 ) is interposed between the punch ( 140 ) and the rim ( 60 ); pressing the punch ( 140 ) against the mounting bracket ( 124 ) so as to deep draw portions of the mounting bracket ( 124 ) and the rim ( 60 ); and attaching the tire-based unit ( 24 ) to the mounting bracket ( 124 ). The deep drawn portion of the mounting bracket ( 124 ) becomes fixed within the deep drawn portion of the rim ( 60 ).

TECHNICAL FIELD

The present invention relates to a method of securing a tire-based unit of a tire condition sensing system to a rim and to an associated apparatus. More particularly, the present invention relates to a method of securing a tire-based unit to a rim using a punch and an associated apparatus.

BACKGROUND OF THE INVENTION

A typical tire condition sensing system for a vehicle includes a vehicle-based unit and a plurality of tire-based units. Each tire of the vehicle has an associated tire-based unit. Each associated tire-based unit senses a condition of its tire and provides a signal to the vehicle-based unit indicative of the sensed parameter. Common tire conditions that are sensed by the tire-based unit include tire pressure and tire temperature.

It is common to secure an associated tire-based unit to the rim upon which its tire is mounted. One known method for securing the tire-based unit to the rim includes extending a strap circumferentially around the rim and securing the tire-based unit to the strap. A potential drawback to the use of the strap, however, is that the strap may slip relative to the rim. This slipping of the strap may affect the balance of the tire.

It is also known to secure a tire-based unit to a rim using an adhesive. Adhesives, however, typically degrade over time, especially when subjected to the temperatures common in a vehicle tire. Also, special surface preparation of the rim may be required for the adhesive to property adhere to the rim.

Another known method attaches a mounting bracket to the rim using rivets. The tire-based unit is secured to the mounting bracket. A drawback of using rivets is that each rivet is associated with a hole that extends through the rim. Air may escape the tire through the associated rivet holes. As a result, the associated rivet holes must be sealed to prevent air leaks.

SUMMARY OF THE INVENTION

The present invention relates to a method of securing a tire-based unit of a tire condition sensing system to a rim. The method comprises the steps of: position a mounting bracket on the rim; positioning a punch against the mounting bracket so that a portion of the mounting bracket is interposed between the punch and the rim; pressing the punch against the mounting bracket so as to deep draw portions of the mounting bracket and the rim, the deep drawn portion of the mounting bracket becoming secured within the deep drawn portion of the rim; and attaching the tire-based unit to the mounting bracket.

In accordance with another aspect, the present invention relates to a method of securing a tire-based unit of a tire condition sensing system to a rim. The method comprises the steps of: position a mounting bracket on the rim; disposing the rim and the mounting bracket in a press between a female mold portion and a punch; pressing the punch against the mounting bracket and toward the female mold portion of the press so as to deep draw portions of the mounting bracket and the rim into the female mold portion to secure the mounting bracket relative to the rim; removing the rim and secured mounting bracket from the press; and attaching the tire-based unit to the mounting bracket.

In accordance with yet another aspect, the present invention relates to an apparatus for a vehicle having a tire condition sensing system. The apparatus comprises a rim upon which a tire of the vehicle is mounted. The apparatus also comprising a tire-based unit of the tire condition sensing system. The tire-based unit includes electronics for sensing a condition of the tire and for transmitting a signal indicative of the sensed condition. The apparatus further comprises a mounting bracket to which the tire-based unit is attachable. The mounting bracket is positioned on the rim. The apparatus still further comprises a punch for securing the mounting bracket to the rim. The punch, when positioned against the mounting bracket and pressed against the mounting bracket, deep draws portions of the mounting bracket and the rim so that the deep drawn portion of the mounting bracket becomes secured within the deep drawn portion of the rim.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features of the present invention will become apparent to those skilled in the art to which the present invention relates upon reading the following description with reference to the accompanying drawings, in which:

FIG. 1 schematically illustrates a vehicle having a tire condition sensing system and apparatuses constructed in accordance with the method of the present invention;

FIG. 2 illustrates an exemplary apparatus of FIG. 1;

FIG. 3 is exploded view of a portion of the apparatus of FIG. 2;

FIG. 4 illustrates a portion of the apparatus of FIG. 2 located in a press during formation of the apparatus; and

FIG. 5 is an enlarged view of a portion of the apparatus of FIG. 2 constructed in accordance with the method of the present invention.

DESCRIPTION OF PREFERRED EMBODIMENT

FIG. 1 schematically illustrates a vehicle 10 including a tire condition sensing system 12. For illustrative purposes, the vehicle 10 of FIG. 1 is an automobile having four tires 16, 18, 20, and 22. Vehicles having a number of tires other than four are also contemplated by the present invention.

The tire condition sensing system 12 of FIG. 1 includes four tire-based units 24, 26, 28, and 30 and a vehicle-based unit 32. Each tire 16, 18, 20, and 22 of the vehicle 10 includes an associated tire-based unit 24, 26, 28, and 30, respectively. Each of the associated tire-based units 24, 26, 28, and 30 includes electronics for sensing at least one condition of the tire and for transmitting a tire condition signal indicative of the sensed condition(s) to a vehicle-based unit 32 of the tire condition sensing system 12. The sensed tire condition(s) may include one or both of inflation pressure and temperature. The transmitted tire condition signals for the tire-based units 24, 26, 28, and 30 are indicated in FIG. 1 as tire condition signals 38, 40, 42, and 44, respectively.

As shown in FIG. 1 with reference to tire-based unit 24, the electronics of tire-based unit 24 include a power source 34 for providing the tire-based unit with electrical energy, a sensor 36 for sensing the at least tire condition, transmitter electronics 46 for providing the associated tire condition signal 38, and an antenna 48 from which the tire condition signal 38 is transmitted. Preferably, the tire condition signal 38 that is transmitted by the tire-based unit 24 is a radio frequency (“RF”) signal. Tire-based units 26, 28, and 30 include electronics similar to those of tire-based unit 24.

The vehicle-based unit 32 includes an antenna 50 that is connected to a receiver 52. Tire condition signals 38, 40, 42, and 44 received by the antenna 50 are demodulated in the receiver 52. Each demodulated tire condition signal is then transferred to a controller 54 of the vehicle-based unit 32. The controller 54 of the vehicle-based unit 32 operates an algorithm for determining whether the received tire condition signal originated from one of the tire-based units 16, 18, 20, and 22 associated with the vehicle 10. The algorithm operated by the controller 54, upon determining that the received tire condition signal originated from one of the tire-based units 24, 26, 28, and 30 associated with the vehicle 10, also determines from which of the tire-based units the tire condition signal originated.

The controller 54 of the vehicle-based unit 32 is operatively connected to a display 56 or other device for providing a vehicle operator with tire condition information. Preferably, the display 56 is located within the occupant compartment of the vehicle 10 and provides the vehicle operator with visual information regarding the tires 16, 18, 20 and 22 of the vehicle.

Each of the tires 16, 18, 20, and 22 of the vehicle 10 is mounted on an associated rim. FIG. 2 illustrates tire 16 mounted on rim 60. The tire-based unit 24 that is associated with tire 16 is secured to the rim 60. The method for securing the tire-based unit 24 to the rim 60 will be discussed in detail below. An apparatus in accordance with the present invention is formed from an assembly of a tire, its associated rim, and its associated tire-based unit. For example, FIG. 2 illustrates apparatus 62 formed from an assembly of tire 16, rim 60, and tire-based unit 24.

For purposes of brevity, the present application will only specifically discuss the method of securing tire-based unit 24 to rim 60, which is associated with tire 16. It should be understood that tire-based units 26, 28, and 30 may be secured to the associated rims of tires 18, 20, and 22 using the same method as is used for securing tire-based unit 24 to rim 60.

FIG. 2 is a cross-sectional view of the apparatus 62. As shown in FIG. 2, the tire-based unit 24 is secured to the rim 60 at a location within tire 16. In the embodiment illustrated in FIG. 2, the rim 60 is formed from metal. The rim 60 may be formed from any malleable material that is suitable for use as a vehicle rim. The rim 60 includes an annular base wall 64. Inner and outer bead flanges 66 and 68 are located on opposite sides of the base wall 64. A drop well 72 extends into the base wall 64 and toward a center (axis A) of the rim 60. The drop well 72 extends circumferentially around the rim 60 and includes a lower wall 74 and opposite side walls 76 and 78.

The tire 16 includes a tread portion 82 and opposite side walls 84 and 86. The side walls 84 and 86 of the tire 16 terminate at ends opposite the tread portion 82 with bead portions 88 and 90, respectively. When the tire 16 is mounted on the rim 60, bead portion 88 seats in bead flange 66 and bead portion 90 seats in bead flange 68. Also, when the tire 16 is mounted on the rim 60, an annular chamber 92 is formed within the tire. The rim 60 defines an interior edge of the annular chamber 92.

FIG. 3 illustrates a portion of the lower wall 74 of the drop well 72. The lower wall 74 has a curved profile that is centered at the center (axis A) of the rim 60. The lower wall 74 includes inner and outer surfaces 102 and 104, respectively. The inner surface 102 is located nearer the center (axis A) of the rim 60 than the outer surface 104. The lower wall 74 has a generally uniform thickness, measured between the inner and outer surfaces 102 and 104.

As shown in FIG. 3, the tire-based unit 24 associated with tire 16 includes a protective housing 108. The protective housing 108 includes a metallic lower portion 110 and a plastic upper portion 112. The lower portion 110 has opposite ends 114 and 116, respectively. A rectangular lock tooth 118 extends outwardly of each of the ends 114 and 116. A cavity (not shown) is formed in the protective housing 108 between the lower portion 110 and the upper portion 112. The electronics of the tire-based unit 24 are located within the cavity. The cavity of the protective housing 108 is subject to the same environmental conditions as the annular chamber 92. For example, the air pressure within the cavity of the protective housing 108 is equal to the air pressure within the annular chamber 92.

A mounting bracket 124 is associated with the tire-based unit 24. The mounting bracket 124 secures the protective housing 108 of the tire-based unit to the rim 60. As is shown in FIG. 2, the tire-based unit 24 is secured to the lower wall 74 of the drop well 72. When secured to the lower wall 74 of the drop well 72, the protective housing 108 of the tire-based unit 24 is located below, or nearer to the center (axis A) of the rim 60, than the annular base wall 64. As a result, when the tire 16 is mounted on the rim 60, the bead portions 88 and 90 of the tire 16 may pass along the annular base wall 64 and over the drop well 72 without contacting the tire-based unit 24.

The mounting bracket 124 is formed from metal or another resilient material. The mounting bracket 124 includes a base portion 126 and opposite end portions 130 and 132, respectively. The base portion 126 of the mounting bracket 124 has a curved profile. The curved profile of the base portion 126 of the mounting bracket 124 corresponds to the curved profile of the lower wall 74 of the drop well 72 of the rim 60, as is illustrated in FIG. 3. The base portion 126 preferably has a width, measured into the paper as viewed in FIG. 3, that is less than half a width of the lower wall 74, measured in a direction parallel to axis A between opposite side walls 76 and 78 of the drop well 72.

The end portions 130 and 132 of the mounting bracket 124 extend from opposite ends of the base portion 126 in a direction radially outward relative to a center of the curved profile of the base portion. A rectangular opening 136 extends through each of the end portions 130 and 132. Each rectangular opening 136 is sized for receiving a rectangular lock tooth 118 of the lower portion 110 of the protective housing 108 of the tire-based unit 24 for securing the tire-based unit to the mounting bracket 124.

FIG. 3 also illustrates two punches 140. The two punches 140 illustrated in FIG. 3 are identical to one another. Each punch 140 is formed as a monolithic body and not from multiple structures secured together. Each punch 140 is formed from a hardened steel.

Each of the punches 140 includes upper and lower portions 142 and 144, respectively. The upper portion 142 includes a flat, circular-shaped upper surface 150. A frustoconical side surface 152 of the upper portion 142 narrows as it extends away from the upper surface 150. The lower portion 144 of the punch 140 includes a flat lower surface 156. The lower surface 156 of the punch 140 has a diameter that is slightly larger than the diameter of the upper surface 150 of the punch. A rounded edge 158 connects the lower surface 156 with a frustoconical side surface 160. The frustoconical side surface 160 of the lower portion 144 narrows as it extends away from the lower surface 156 and toward the upper surface 150. The frustoconical surfaces 152 and 158 meet at a neck portion 162 of the punch 140. The neck portion 162 of the punch 140 forms the narrowest portion of the punch.

The two punches 140 are used for deep drawing the mounting bracket 124 and the rim 60 to secure the mounting bracket relative to the rim. A number of punches 140 other than two may be used. By using the punches 140 in accordance with the method of the present invention, the mounting bracket 124 may be secured to the rim 60 without the rim being penetrated and without the rim requiring special surface preparation.

To secure the mounting bracket 124 to the rim 60, the base portion 126 of the mounting bracket 126 is positioned on the outer surface 104 of the lower wall 74 of the drop well 72 of the rim 60. Preferably, the mounting bracket 124 is positioned at equal distances from each of the side walls 76 and 78 of the drop well 72. The rim 60 and the mounting bracket 124 are then positioned in a press 168 (FIG. 4) having a female mold portion 170 and a plunger portion 172. The rim 60 and the mounting bracket 124 are positioned in the press 168 at a location between the female mold portion 170 and the plunger portion 172. FIG. 4 illustrates the lower wall 74 of the drop well 72 and the mounting bracket 124 being interposed between the female mold portion 170 and the plunger portion 172.

The female mold portion 170 of the press 168 includes an upper surface 178 upon which the inner surface 102 of the lower wall 74 of the drop well 72 is positioned. Preferably, the upper surface 178 of the female mold portion 170 has a curved profile that corresponds to the curved profile of the inner surface 102 of the lower wall 74 of the drop well 72 of the rim 60. A cavity 180 extends into the upper surface 178 of the female mold portion 170. The cavity 180 is generally cylindrical and is defined by an annular side surface 182 and a circular lower surface 184 of the female mold portion 170. A curved shoulder 186 connects the annular side surface 182 to the circular lower surface 184. The cavity 180 has a depth, measured generally in the vertical direction as viewed in FIG. 4, that is approximately equal to the height of the punch 140. The height of the punch 140 is a distance between the upper and lower surfaces 150 and 156 of the punch. The cavity 180 has a width, measured generally horizontally as viewed in FIG. 4, that is larger than the diameter of the lower surface 156 of the punch 140.

The punch 140 is positioned on the base portion 126 of the mounting bracket 124 at a location above the cavity 180 of the female mold portion 170. When positioned on the mounting bracket 124, the lower surface 156 of the punch 140 abuts the base portion 126 of the mounting bracket 124 and the upper surface 150 of the punch is engaged by the plunger portion 172 of the press 168. Thus, as shown in FIG. 4, the rim 60, the mounting bracket 124, and the punch 140 are interposed between the female mold portion 170 and the plunger portion 172 of the press 168.

Next, the press 168 is actuated so that the plunger portion 172 presses the punch 140 against the mounting bracket 124 and toward the cavity 180 of the female mold portion 172. As the punch 140 is pressed toward the cavity 180 of the female mold portion, portions of the base portion 126 of the mounting bracket 124 and the lower wall 74 of the drop well 72 of the rim 60 are drawn, or deep drawn, about the punch 140 and into the cavity 180 of the female mold portion 170. When deep drawn into the cavity 180, the mounting bracket 124 and the lower wall 74 of the rim 60 are deformed to fill the space within the cavity 180 between the surfaces 182, 184, and 186 of the female mold portion 170 and the punch 140. As a result, the deep drawn portions of the mounting bracket 124 and the lower wall 74 narrow at the portion neck 162 of the punch 140, as can be seen with reference to FIG. 5. When the deep drawn portions of the mounting bracket 124 and the lower wall 74 narrow at the neck portion 162 of the punch 140, the deep drawn portion of the mounting bracket 124 becomes secured within the deep drawn portion of the lower wall 74 of the drop well 72 of the rim and between the lower wall and the punch 140.

After the base portion 126 of the mounting bracket 124 is secured to the lower wall 74 of the drop well 72 of the rim 60, the rim 60 and mounting bracket 124 are removed from the press 168. The method of the invention is repeated for securing the mounting bracket 124 to the rim 60 with additional punches 140.

After all of the punches 140 have been pressed into positions securing the mounting bracket 124 to the rim 60, the protective housing 108 of the tire-based unit 24 is attached to the mounting bracket. To attach the protective housing 108 to the mounting bracket 124, the rectangular lock tooth 118 on the end 114 of the lower portion 110 of the protective housing 108 is inserted through the rectangular opening 136 in the end portion 130 of the mounting bracket 124. The protective housing 108 is then pressed downward toward the base portion 126 of the mounting bracket 124 so that the rectangular lock tooth 118 on the end 116 of the lower portion 110 of the protective housing 108 snaps into the rectangular opening 136 in the end portion 132 of the mounting bracket 124. The tire 16 is then mounted on the rim 60 in a known manner. The apparatus 62, which includes the rim 60, the tire 16, and the secured tire-based unit 24, is then ready for assembly onto the vehicle 10 having the tire condition sensing system 12.

From the above description of the invention, those skilled in the art will perceive improvements, changes and modifications. Such improvements, changes and modifications within the skill of the art are intended to be covered by the appended claims. 

1. A method of securing a tire-based unit of a tire condition sensing system to a rim, the method comprising the steps of: positioning a mounting bracket on the rim; positioning a punch against the mounting bracket so that a portion of the mounting bracket is interposed between the punch and the rim; pressing the punch against the mounting bracket so as to deep draw portions of the mounting bracket and the rim, the deep drawn portion of the mounting bracket becoming secured within the deep drawn portion of the rim; and attaching the tire-based unit to the mounting bracket.
 2. The method of claim 1 wherein the step of positioning the mounting bracket further includes the step of positioning the mounting bracket in a drop well of the rim.
 3. The method of claim 2 further including the step of positioning the mounting bracket on a lower wall of the drop well of the rim.
 4. The method of claim 2 wherein the step of attaching the tire-based unit further includes the step of positioning the tire-based unit in the drop well of the rim so that the tire-based unit is located nearer a center of the rim than an annular wall of the rim into which the drop well extends.
 5. The method of claim 1 wherein the step of positioning the mounting bracket further includes the steps of placing a base portion of the mounting bracket on a surface of the rim having an curved profile that corresponds to a curved provide of the base portion.
 6. The method of claim 1 wherein the step of pressing the punch further includes the step of securing the deep drawn portion of the mounting bracket between the punch and the deep drawn portion of the rim.
 7. The method of claim 1 wherein the step of pressing the punch further includes the step of deep drawing portions of the mounting bracket and the rim toward a center of the rim.
 8. The method of claim 1 wherein the step of pressing the punch further includes the step of forcing the punch toward a female mold portion of a press so that portions of the mounting bracket and the rim are deep drawn into the female mold portion.
 9. The method of claim 8 further including the steps of providing a punch having a narrowed neck portion located near a center of the punch; and fixing the mounting bracket relative to the rim by deep drawing portions of the mounting bracket and the rim over the narrowed neck portion of the punch.
 10. The method of claim 1 wherein the step of attaching the tire-based unit further includes the steps of inserting a first lock tooth of the tire-based unit into an associated opening in the mounting bracket; pressing the tire-based unit toward the base portion of the mounting bracket; and snapping a second lock tooth of the tire-based unit into an associated opening in the mounting bracket.
 11. A method of securing a tire-based unit of a tire condition sensing system to a rim, the method comprising the steps of: position a mounting bracket on the rim; disposing the rim and the mounting bracket in a press between a female mold portion and a punch; pressing the punch against the mounting bracket and toward the female mold portion of the press so as to deep draw portions of the mounting bracket and the rim into the female mold portion to secure the mounting bracket relative to the rim; removing the rim and secured mounting bracket from the press; and attaching the tire-based unit to the mounting bracket.
 12. The method of claim 11 wherein the step of positioning the mounting bracket further includes the step of positioning the mounting bracket in a drop well of the rim.
 13. The method of claim 12 wherein the step of attaching the tire-based unit further includes the step of positioning the tire-based unit in the drop well of the rim so that the tire-based unit is located nearer a center of the rim than an annular wall of the rim into which the drop well extends.
 14. The method of claim 11 wherein the step of pressing the punch further includes the step of deep drawing portions of the mounting bracket and the rim toward a center of the rim.
 15. The method of claim 11 wherein the step of attaching the tire-based unit further includes the steps of inserting a first lock tooth of the tire-based unit into an associated opening in the mounting bracket; pressing the tire-based unit toward the base portion of the mounting bracket; and snapping a second lock tooth of the tire-based unit into an associated opening in the mounting bracket.
 16. An apparatus for a vehicle having a tire condition sensing system, the apparatus comprising: a rim upon which a tire of the vehicle is mounted; a tire-based unit of the tire condition sensing system, the tire-based unit including electronics for sensing a condition of the tire and for transmitting a signal indicative of the sensed condition; a mounting bracket to which the tire-based unit is attachable, the mounting bracket being positioned on the rim; and a punch for securing the mounting bracket to the rim, the punch, when positioned against the mounting bracket and pressed against the mounting bracket, deep drawing portions of the mounting bracket and the rim so that the deep drawn portion of the mounting bracket becomes secured within the deep drawn portion of the rim.
 17. The apparatus of claim 16 wherein the rim including an annular wall, a drop well extending into the annular wall, the mounting bracket being secured to the rim in the drop well.
 18. The apparatus of claim 17 wherein the tire-based unit, when attached to the mounting bracket, is located in the drop well of the rim, the tire-based unit being located nearer a center of the rim than the annular wall of the rim.
 19. The apparatus of claim 16 wherein the punch includes a narrowed neck portion that is located near a center of the punch, the deep drawn portions of the mounting bracket and the rim extending over the narrowed neck portion of the punch for securing the mounting bracket relative to the rim.
 20. The apparatus of claim 15 wherein the mounting bracket includes opposite end portions, each of the end portions including an opening, the tire-based unit including a housing having opposite ends, a lock tooth ending outward of each end of the housing, the lock teeth of the housing being received in the openings of the end portions of the mounting bracket for attaching the tire-based unit to the mounting bracket. 